US10513010B2 - Control of particle supply of blasting apparatus - Google Patents

Control of particle supply of blasting apparatus Download PDF

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US10513010B2
US10513010B2 US15/539,794 US201615539794A US10513010B2 US 10513010 B2 US10513010 B2 US 10513010B2 US 201615539794 A US201615539794 A US 201615539794A US 10513010 B2 US10513010 B2 US 10513010B2
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flow
blasting
throughput
feed
manipulated variable
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US20180264625A1 (en
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Volker Schneidau
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Sentenso GmbH
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Sentenso GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C7/00—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts
    • B24C7/0007—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a liquid carrier
    • B24C7/0015—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a liquid carrier with control of feed parameters, e.g. feed rate of abrasive material or carrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C7/00—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
    • B24C7/00—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts
    • B24C7/0046—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a gaseous carrier
    • B24C7/0053—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a gaseous carrier with control of feed parameters, e.g. feed rate of abrasive material or carrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B57/00—Devices for feeding, applying, grading or recovering grinding, polishing or lapping agents
    • B24B57/04—Devices for feeding, applying, grading or recovering grinding, polishing or lapping agents for feeding of solid grinding, polishing or lapping agents
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working

Definitions

  • the invention relates to a method of adjusting or operating a particle-metering system of a particle-blasting apparatus, particularly of a blasting apparatus for treating a surface where the particle throughput is preset by a feed orifice that can be varied with respect to time and/or variables and is determined by a downstream flow sensor generating a flow-sensor signal (DS), with the flow-sensor signal (DS) being used to control a manipulated variable (SG) for the output setting of the feed orifice.
  • DS flow-sensor signal
  • SG manipulated variable
  • the particle throughput that is outputted to a workpiece for the purpose of working it is controlled via a feed assembly.
  • This feed assembly is generally between a supply vessel in which the blasting particles is held and a system through which the blasting particles is accelerated and guided toward a workpiece.
  • a compressed-air system or an impeller wheel is usually used to accelerate the blasting particles. Due to irregularities in the throughput of the blasting particles through the feed assembly, the particle throughput that is fed to the workpiece may not be constant. Such fluctuations in the particle throughput can be caused by nonuniform flow characteristics or other changing physical conditions during operation of the blasting apparatus.
  • a device is proposed in DE 102014201913 [US 2014/0220861] in which the particle throughput is maintained constant by variably controlling the opening of a valve in order to increase or reduce the throughput that is measured by a detection device.
  • a baffle plate sensor is used as a detection device for determining the particle throughput from the deflection of a deflectable member, and the electrical characteristics of the particle material are unimportant in this measurement method.
  • the signal of the baffle plate sensor is used to control how much the valve is opened, and the flow cross section is varied mechanically such that a constant quantity of blasting particles per unit of time is supplied.
  • This principle for controlling the particle throughput is also used in a comparable manner with other detection devices and variable feed orifices.
  • the drawback of this solution is that, when the composition of the blasting particles changes and the physical characteristics change as a result, the detection device measures a throughput value that does not match the actual throughput. As a result, the right quantity of blasting particles for the blasting process is not fed to the workpiece.
  • a change in the composition of the blasting particles can be brought about deliberately by changing the type of blasting particles, or it can change inadvertently as a result of contaminants or modification of the blasting particles as a result of repeated use.
  • This object is achieved by a method in which, in order to adjust the feed assembly for at least one manipulated variable (SG), the actual throughput (D) through the variable feed orifice is determined by measuring the weight of the outputted blasting particles (M) within a defined time period (Dt), and the manipulated variable (SG), the actual throughput (D), and the corresponding flow-sensor signal (DS) are stored in an allocation table, with the relationships between the actual throughput (D), the manipulated variable (SG), and the flow-sensor signal (DS) being used during subsequent operation.
  • the generation of the allocation table offers the advantage that a manipulated variable (SG) can be preset during the operation of the feed assembly following adjustment that corresponds to the actual required throughput (D). As a result, the particle throughput through the feed assembly takes on the required value, thus ensuring the desired processing quality during the blasting process.
  • SG manipulated variable
  • a functional correlation is calculated between the manipulated variable (SG) and the actual throughput (D) from the allocation table generated during the adjustment, in which, for a discrete number of values for the manipulated variable (SG), the corresponding actual throughput (D) and the corresponding flow-sensor signal (DS) are stored.
  • a manipulated variable (SG) is extrapolated that corresponds or comes closest to the respective actual required throughput (D) even if a value is required for the actual throughput that is not stored as a discrete value in the allocation table. Consequently, an appropriate manipulated variable (SG) is available for controlling the feed orifice for every required throughput (D) that can be outputted by the feed assembly.
  • the actual throughput (D) is calculated from the allocation table as a function of the flow-sensor signal (DS). This makes it possible to determine the actual throughput (D) at least approximately for a measured flow-sensor signal (DS) that is not stored in the allocation table.
  • the actual throughput (D) can thus be determined directly during operation from the flow-sensor signal (DS) and used to control or indicate and/or record the actual throughput (D).
  • a linear extrapolation is performed between the discrete values of the allocation table. This is a simple mathematical operation that can be performed with little computing power and can therefore be carried out relatively quickly during control with or without feedback.
  • the manipulated variable (SG) as a function of the actual throughput (D) and the actual throughput (D) as a function of the flow-sensor signal (DS) is approximated by a polynomial.
  • a polynomial In order to at least roughly approximate the polynomial to the discrete values of the allocation table, it is necessary to use at least a second-order polynomial. It was found that approximation by a fourth-order polynomial usually ensures an adequate approximation to the discrete values of the allocation table with relatively little computing power.
  • the discrete values of the allocation table are correlated using a polynomial calculation. This is also an arithmetic operation that is associated with reasonable computational complexity and enables an adequate approximation to the discrete measured values of the allocation table.
  • the manipulated variable (SG) in order to adjust the feed assembly, is altered by a program in discrete steps, and the actual throughput (D), the flow-sensor signal (DS), and the respective manipulated variable (SG) are stored in the allocation table for each discrete step.
  • the adjustment range of the manipulated variable (SG) is divided into a defined number of equidistant steps, and the respective values of the manipulated variable (SG) are triggered successively in time.
  • the number of steps depends on the available adjusting time and the required accuracy of the allocation, with a subdivision into ten or twenty steps being preferred.
  • several measured values, each with a measuring time period (Dt) are recorded for each discrete step of the manipulated variable (SG), and the average of the measured values is stored in the allocation table. This procedure enables the allocation table to be generated automatically, thus minimizing the personnel and time required for the adjustment.
  • a corresponding allocation table is prepared for each of the blasting abrasives used. During operation of the blasting apparatus, the corresponding allocation table is then used to control the feed assembly with or without feedback. This ensures during operation, when there is a change to a blasting abrasive that is already known, no adjustment of the feed assembly need be carried out but the required abrasive throughput will reach the workpiece to be processed nonetheless.
  • the feed assembly is controlled at the start of the blasting process such that the corresponding manipulated variable (SG) is calculated for the actual required throughput (D) from the allocation table that was defined during the adjustment and applied to the feed orifice.
  • the manipulated variable (SG) of the feed orifice is then regulated with respect to the measured flow-sensor signal (DS) such that the throughput remains constant.
  • DS measured flow-sensor signal
  • the actual throughput (D) is determined during operation of the feed assembly based on the throughput signal (DS) from the allocation table. During operation, the actual throughput (D) is thus either indicated via a display and/or recorded, and regulation is performed to a required throughput level.
  • environmental conditions such as ambient temperature, air pressure, and air humidity are measured during operation and a correction value is determined from this measurement with which the flow-sensor signal (DS) and/or the manipulated variable (SG) from the allocation table are multiplied.
  • the altered environmental conditions and their influence on the feed assembly are thus taken into account.
  • Determination of the correction factor is based on a correlation between flow-sensor signal (DS) and manipulated variable (SG) and the environmental conditions that is determined by measurement or calculated mathematically. This offers the advantage of enabling behavior of the feed assembly that is dependent on environmental conditions to be compensated for.
  • a switch is performed automatically between adjustment and operation by either feeding the blasting particles onto a workpiece or into a collecting vessel. This makes it possible to still feed the desired quantity of blasting particles to the workpiece during operation even when the blasting particles are changed or in the case of wear-related changes in the blasting particles and the associated physical characteristics. This is advantageous particularly in production lines, since a quicker adjustment can be made, thus resulting in shorter down time.
  • the weight of the blasting particles (M) is measured in the present invention in an advantageous manner by measuring the increase in the weight of a collecting vessel into which the blasting particles are fed or the decrease in the weight of a supply vessel from which the blasting particles are drawn.
  • the measurement of the decrease in weight offers the advantage that the weight of the blasting particles leaving the supply vessel through the feed orifice is measured directly without a time delay until it reaches a collecting vessel.
  • the measurement of the decrease in the weight of the supply vessel has the disadvantage in the case of large and/or heavy supply vessels that the accuracy of the measurement is limited as a result. In this case, it is advantageous if any delays before the collecting vessel is reached are conceded and the weight increase of the collecting vessel is measured, since that is substantially smaller in corresponding measurement time periods (Dt) and can be measured more easily and with greater precision.
  • a certain throughput level is required in order to check the adjustment of the blasting apparatus, and the actual throughput through the feed assembly is determined by measuring the weight of the outputted blasting particles (M) within a defined time period (Dt).
  • an appropriate manipulated variable (SG) is calculated for the required throughput from the allocation table that was generated during the adjustment and applied to the feed orifice.
  • a direct check of the adjustment is performed immediately after the adjustment. If the throughput required in this case does not match with the throughput that is actually measured, then it is necessary to regenerate the allocation table with a greater number of discrete steps of the manipulated variable (SG) or to perform a more precise calculation of the functional correlation between the values from the allocation table. A more exact calculation of the functional correlation is preferably performed through approximation with a higher-order polynomial.
  • the direct check ensures that a precise adjustment has been carried out before the operation of the blasting apparatus that satisfies the requirements.
  • a check of the adjustment is also advantageously performed after a certain period of operation during stoppages. In this case, if the required throughput does not match with the actual throughput, then another adjustment with generation of the allocation table is necessary. Regular checking of the adjustment enables operation-related influences on the feed assembly and changes in the blasting particles to be taken into account and compensated for by readjustment. Performing a check has the advantage that the generation of a complete allocation table is only done as needed, which saves time and other resources.
  • the method described is preferably used in n particles-blasting apparatus having a supply vessel that is connected via a feed assembly to an outlet.
  • the feed assembly consists of a feed orifice that can be varied with respect to time and/or variables and a flow sensor arranged downstream.
  • the blasting apparatus has a collecting vessel with a weight detector that receives the blasting particles from the feed assembly.
  • the feed assembly is connected to a processor that regulates the feed orifice that can be varied based on time and/or variables and reads out the flow sensor. In order to evaluate the weight detector and control the processor, the latter is connected to a computer.
  • the weight of the blasting particles is measured within a defined time period, and the actual throughput is determined using the method described above.
  • the corresponding regulation and control of the feed assembly is carried out by a computer in conjunction with the processor.
  • a mechanically adjustable flow section or a solenoid valve can be used as the feed orifice that can be varied with respect to time and/or variables.
  • a solenoid valve is preferably used in which the blasting particles are hindered by an applied magnetic field while flowing through the feed orifice and opened through the application of an additional compensating magnetic field.
  • the throughput is especially preferably performed by a pulse duration modification, with the on/off ratio being proportional to the actuating variable.
  • the flow sensor is a microwave sensor, an ultrasonic sensor, a baffle plate sensor, an induction sensor, or a capacitance sensor. Due to the simple and robust design, induction sensors or capacitance sensors are preferably used as flow sensors in the present invention.
  • an upstream separator is used in which the blasting particles are separated from other process materials and fed in its entirety into the collecting vessel.
  • a cyclone can be especially preferably used as a separator in order to separate the blasting particles from the air.
  • the air is separated from the blasting particles and fed through a funnel into the collecting vessel. This is advantageous particularly if the blasting particles are already traveling at a high speed and simply guiding it into the collecting vessel would distort the measuring result.
  • a separator it is possible to switch between adjustment and normal operation by inserting a deflector between the outlet and the feed assembly that guides the blasting particles either into the separator or onto the workpiece to be blasted.
  • the deflector can be embodied as a robot that guides the outlet for the blasting particles either into the separator or onto the workpiece.
  • Such an arrangement can be preferably converted into a production facility in which switching is performed automatically between adjustment and operation. As a result, automated adjustment can be performed, which reduces the down times of the production facility.
  • the processor is connected to a computer, regulates the variable feed orifice, and reads out the flow sensor.
  • the processor has an either digital or analog manipulated variable interface and a flow sensor interface in order to connect to the feed orifice and the flow sensor.
  • the interfaces are additionally connected by an analog-to-digital converter to a microcontroller that takes over control of the feed assembly.
  • the microcontroller stores the allocation table in a memory and is connected to a digital computer interface and/or an interface to a machine control by means of which the processor is controlled.
  • FIG. 1 shows a particle-blasting apparatus as it is used to adjust the feed assembly, with the weight detector being connected to a collecting vessel;
  • FIG. 2 shows a particle-blasting apparatus as used to adjust the feed assembly, with the weight detector being connected to a supply vessel;
  • FIG. 3 shows the entries of the allocation table
  • FIG. 4 a shows a linear interpolation of the actual throughput (D) as a function of the manipulated variable (SG);
  • FIG. 4 b shows a flow-sensor signal (DS) as a function of the actual throughput (D), which is approximated by a polynomial;
  • FIG. 5 shows a particle-blasting apparatus with integrated conversion between adjustment and operation
  • FIG. 6 shows an overview of a processor.
  • FIG. 1 shows a particle-blasting apparatus 1 in which the blasting particles 2 are held in a supply vessel and is delivered from same via an outlet 4 .
  • the feed assembly 5 which consists of a feed orifice 6 that can be varied with respect to time and/or variables, as well as a downstream flow sensor 7 , is between the supply vessel 3 and the outlet 4 .
  • the quantity of blasting particles 2 that leaves the supply vessel 3 is predefined by the output setting of the feed orifice 6 and measured by the flow sensor 7 .
  • the blasting particles are fed into a collecting vessel 8 and its weight (M) is measured by a weight detector 9 .
  • An output of the weight detector 9 is evaluated by a computer 10 , and the throughput (D) through the outlet 4 is determined as the weight of the blasting particles allowed to pass through within a defined time period (Dt).
  • the output setting of the variable feed orifice 6 is predefined by the processor 11 as a manipulated variable (SG), with the processor 11 simultaneously also reading out the flow-sensor signal (DS) of the flow sensor 7 .
  • the feed assembly is adjusted by simultaneous measurement of the actual throughput (D) via the weight detector 9 and measurement of the flow-sensor signal (DS) by the flow sensor 7 with values for the manipulated variable (SG) of the feed orifice 6 predefined by a program.
  • FIG. 2 shows another embodiment of the invention where, unlike the particle-blasting apparatus 1 of FIG. 1 , a weight detector 9 is connected to the supply vessel 3 .
  • the weight of the blasting particles that flows through the feed orifice 6 is determined by having the weight detector 9 measure the decrease in the weight of the supply vessel 3 .
  • this has the advantage that the weight is measured directly as the blasting abrasive flows out of the outlet 4 , and a time delay pending the arrival of the blasting particles in the collecting vessel 8 is avoided.
  • This arrangement is advantageous particularly if the supply vessel and its contents have has a weight that can be determined with sufficient accuracy without great effort and is therefore used in a particle-blasting apparatus in which a small quantity of readied blasting particles suffices.
  • the arrangement of a particle-blasting apparatus 1 as in FIG. 2 is used exclusively for adjusting or checking a feed assembly 5 .
  • a feed assembly that is to be used in the future during operation is first inserted into a particle-blasting apparatus 1 according to FIG. 2 between the supply vessel 3 and the outlet 4 , and an allocation table between the manipulated variable (SG), the actual throughput (D), and the flow-sensor signal (DS) is then generated and stored according to the above-described method.
  • the allocation table is then used during the operation of the current feed assembly 5 , which is for example installed in a production unit in order to control same with or without feedback. Due to the relatively small quantity of blasting particles required for adjustment, the decrease in the weight of the supply vessel 3 can be easily measured during the adjustment, and a time-delay pending the arrival of the blasting particles in the collecting vessel 8 is irrelevant.
  • the recorded values of the actual throughput (D), the flow-sensor signal (DS), and the manipulated variable (SG) are stored in the allocation table whose entries are shown in FIG. 3 .
  • the number of preset values of the manipulated variable (SG) is arbitrary and can be selected as a function of the composition of the blasting particles, the required or available adjustment time, and the required precision.
  • the allocation table is stored in the processor 11 and/or in the computer 10 . During operation of the feed assembly 5 with a required actual throughput (D), the corresponding manipulated variable (SG) is read out from the allocation table, so that the actual required throughput is transmitted to the working process at the outlet 4 during operation.
  • the allocation table is used during operation of the particle-blasting apparatus 1 to determine the actual throughput (D) from the measured flow-sensor signal (DS) of the flow sensor 7 .
  • FIG. 4 a shows how a correlation between the manipulated variable (SG) and the actual throughput (D) is calculated from the discrete measured values of the allocation table by linear interpolation.
  • the manipulated variable (SG) is determined as a function of the throughput (D), so that a value for the manipulated variable (SG) at an actual required throughput (D) is also available between the discrete measured values.
  • FIG. 4 b shows how a functional correlation between the throughput (D) and the flow-sensor signal (DS) is calculated from the discrete values of the allocation table through approximation via a polynomial.
  • the actual throughput (D) through the outlet 4 is determined from this functional correlation from the measured flow-sensor signal (DS).
  • FIG. 5 shows a particle-blasting apparatus as used during operation.
  • the blasting particles 2 are located in the supply vessel 3 and passes through the feed assembly 5 toward an outlet 4 , with a deflector 12 between the outlet 4 and the feed assembly 5 that deflects the blasting particles either into a separator 13 or onto a workpiece 14 .
  • the separator 13 the blasting particles are separated from other process materials and recovered completely by the collecting vessel 8 .
  • the weight of the blasting particles (M) is measured by a weight detector 9 .
  • the throughput (D) through the feed orifice 6 is determined by the computer 10 by determining the weight of the blasting particles (M) emitted within a defined time period (Dt).
  • the blasting particles 2 are accelerated by an air compressor 15 , thereby achieving the desired process result during the blasting of the workpiece 14 .
  • the blasting apparatus 1 is integrated into a production line by connecting the processor 11 to a higher-level machine control 16 .
  • the ambient conditions such as temperature, air pressure, and air humidity are measured by the sensor unit 17 .
  • the ambient conditions are compensated for during operation by multiplying the manipulated variable and/or the flow-sensor signal from the allocation table by a correction function that is dependent on the ambient conditions.
  • the collecting vessel 8 from FIG. 5 is embodied as a funnel-shaped collecting vessel on whose funnel neck a check valve is mounted. At the end of the adjustment procedure, the check valve is opened and the blasting particles located in the funnel-shaped collecting vessel is guided into the collecting vessel 3 and supplied for further processing.
  • FIG. 6 illustrates an advantageous embodiment of the processor 11 that controls the variable feed orifice 6 and reads out the flow sensor 7 .
  • the processor 11 has a manipulated variable interface 18 for the manipulated variable and a flow sensor interface 19 for the flow-sensor signal (DS). These interfaces are either analog or digital.
  • additional analog-to-digital converters 20 are used in order to connect to a microcontroller 21 .
  • the microcontroller 21 has a memory 22 and/or is connected thereto; it is here that the specific allocation table is stored and called up during adjustment.
  • the connection of the processor 11 to the computer 10 is achieved via a computer interface 23 .
  • a connection to the controller 16 is achieved via a machine interface 24 .
  • the sensor unit 17 is read out via an ambient sensor interface 27 , and the ambient conditions of temperature, air pressure, and air humidity are taken into account by the processor 11 when controlling and/or regulating the feed assembly 5 .
  • the machine interface 24 has a digital signal for calling up the table, a digital enable signal for the feed orifice, an analog control signal, and an analog throughput signal. Using these signals, it is easy to integrate the processor into a higher-level memory-programmable or computer-based controller.
  • the manipulated variable interface 18 has an additional digital enable signal that enables the opening of the feed orifice 6 as needed. An additional safety function is thus ensured and inadvertent releasing of the blasting particles prevented during operation.
  • the processor 11 further comprises an operator control module 25 , which is provided to set operating modes of the processor, as well as a display unit 26 that displays the status of the processor 11 and outputs operating parameters.
  • the weight detector is read out directly via the processor.
  • the processor 11 is advantageously integrated physically into the feed assembly 5 .
  • This embodiment of the invention offers the advantage that a connection between processor 11 and feed assembly 5 via the manipulated variable interface 18 and the flow sensor interface 19 is not needed. A physically more compact construction is thus achieved.
  • control function of the processor and the computer is taken over directly by a memory-programmable or computer-based higher-level controller.
  • the corresponding interfaces to the feed assembly and to the weight detector as well as the memory for the allocation table are supplied by the higher-level controller.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
US15/539,794 2015-01-22 2016-01-21 Control of particle supply of blasting apparatus Active 2036-05-14 US10513010B2 (en)

Applications Claiming Priority (4)

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DE102015000632 2015-01-22
DE102015000632.0A DE102015000632A1 (de) 2015-01-22 2015-01-22 Regelung des Strahlmitteldurchsatzes einer Strahlanlage
DE102015000632.0 2015-01-22
PCT/EP2016/000110 WO2016116277A1 (fr) 2015-01-22 2016-01-21 Régulation du débit d'agent de sablage dans une installation de sablage

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US10513010B2 true US10513010B2 (en) 2019-12-24

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US20180264625A1 (en) 2018-09-20
WO2016116277A1 (fr) 2016-07-28

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